Modular insulated panel system

ABSTRACT

A modular insulated panel system in which a series of panels are assembled together with panel locking and sealing members to form an enclosed insulated space adapted for different environmental conditioning than the contiguous area.

United States Patent 91 Baruzzini [451 May 1, 1973 MODULAR INSULATEDPANEL SYSTEM [75] Inventor: Gino L. Baruzzini, OFallon, M0.

[73] Assignee: Pet Incorporated, St. Louis, Mo.

[22] Filed: Sept. 14, 1970 [21] App1.No.: 71,735

[52] US. Cl. ..52/264, 52/481, 52/586,

52/403 [51] Int. Cl ..E04b 1/343, E04b 1/38 [58] Field of Search..52/264, 272 275,

[56] References Cited UNITED STATES PATENTS 1,021,867 4/1912 Goss..52/711 2,137,767 11/1938 Betcone ..52/274 2,143,288 1/1939 Stolz..287/189.36 D 2,223,016 11/1940 Parkhurst ..52/584 2,988,855 6/1961Asfour et al..... .....52/711 3,392,497 7/ 1 968 Cushman ..52/5843,508,369 4/1970 Tennison ..52/43 3,570,205 3/1971 Payne ..52/4032,966,967 1/1961 Levy et al ..52/36 3,397,428 8/1968 Donald ..264/1713,448,183 6/1969 Chisholm .....264/171 3,490,800 1/1970 Wissler ..52/5863,512,819 5/1970 Morgan et a1. ...52/309 3,564,801 2/1971 Huerta...52/309 3,626,652 12/1971 Hanley .l ..52/586 FOREIGN PATENTS ORAPPLICATIONS 46,857 8/1936 France ..52/495 761,444 1/1934 France...52/481 769,067 6/1934 France ..52/481 775,877 10/1934 France ..52/4791,336,243 7/1963 France ..52/403 1,452,891 8/1966 France ..52/3931,354,946 2/1964 France ..52/613 Primary Examiner-Frank L. AbbottAssistant Examiner.lames L. Ridgill, Jr. Att0rney-Richard G. Heywood[57] ABSTRACT A modular insulated panel system in which a series ofpanels are assembled together with panel locking and sealing members toform an enclosed insulated space adapted for different environmentalconditioning than the contiguous area.

13 Claims, 39 Drawing Figures Patented May 1, 1973 13 Sheets-Sheet 2FIG.3

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FIG 4 Patented May 1, 1973 3,729,889

l3 Sheets-Sheet 5 PF F1521 Q ZL/flAL M-W Patented May 1, 1973 13Sheets-Sheet 6 a w m n r. P 0 Z? .5 m 1 d WZ IW 0 4 V v c 4 4 n wa d I u4 I] w 0 e H 4 4 a 0 A -///w/ a: kld V! w a 2 2 [H 2 ll G n H A Z Patented May 1, 1973 13 sheets-sheet 9 mm UE 6/ 1.3 67 Z/lY/ 24i? PatentedMay 1, 1973 13 Sheets-Sheet 10 III 19702.

Patented May 1, 1973 3,729,889

13 Sheets-Sheet 11 zwz 4M Patented May 1, 1973 3,729,889

13 Sheets-Sheet 13 MODULAR INSULATED PANEL SYSTEM BACKGROUND OF THEINVENTION The invention relates generally to panel systems formingpartition walls or complete enclosures, and more particularly toinsulated or isolated spaces having a controlled environment.

Many panel systems have been developed for installation in differenttypes of facilities and for use by a wide variety of businesses orindustries in which prefabricated partition walls or complete enclosuresare required to form separate adjoining areas such as office cubicles,laboratory and research facilities, warehousing or storage facilities,production facilities, treatment rooms and the like. In many cases, itis essential or highly desirable to sound-proof certain areas or tomaintain different environmental conditions such as temperature,humidity, atmosphere and the like. It is manifest that the conditions ofuse will usually dictate the minimum requirements and specifications ofany panel system and factors of strength, rigidity, durability,appearance, etc. will thus be determined. In panel systems formingenclosed spaces in which environmental control is to be effected, theintegrity of the sealing arrangement is a major factor to maintain auniform temperature gradient or minimize moisture migration or otherinterchange of atmosphere except as may occur naturally as a resultofingress or egress.

Without limitation upon the scope of the panel system invention to otherapplications in different industries, a typical and preferred embodimentof the present modular insulated panel system invention hereinafterselected for purposes of illustration and disclosure comprises arefrigerated enclosure of the type known in the refrigeration industryas a walk-in cooler. Such coolers may be installed in supermarkets ornumerous other types of businesses for the storage of merchandise underrefrigeration or other environmental conditioning than the adjoiningarea in which the cooler is installed. In the past such walk-in coolershave been fabricated with wall panels having a wooden frame within whichan insulating material has been packed and covered by outerporcelainized metallic casing or liner sheets secured by an adhesivebonding material. These panels were secured together by spaced camlocking devices recessed into the wooden frame and accessible throughexterior ports, with sealing gaskets being provided on adjacent abuttingsurfaces. Conventional wood or metal flooring has been utilized andceiling or top panel structures were similar. Such panel systems, asothers used in industry, have been expensive to build with problems ofmaintaining manufacturing tolerances and quality control, have beenexpensive to ship and handle due to the weight and bulk thereof, andhave been expensive to install for like reasons.

SUMMARY OFTHE INVENTION component parts, novel panel locking membersinsertable into opposed channel means of adjacent panel members ininterlocking relationship, and novel sealing members applied betweenadjacent panel members.

The principal object of the present invention is to provide a novelpanel system permitting the orientation and assembly of panel membersinto various arrangements of partition walls and complete enclosureshaving sound-proof or insulation characteristics adapting the delimitedarea for environmental control.

Another object of the invention is to provide a panel system utilizingpanels fabricated in a novel manner and having optimum strength,rigidity, and insulation characteristics, and which are light weight andeconomically manufactured, stored, shipped and handled. It is also anobject to provide a panel system forming a complete insulated enclosurethat may quickly and easily be assembled with minimum manpower, time andtools.

Another object is to provide a novel panel inter locking arrangement forpositive engagement between adjacent panels and structural strengtheningthereof.

Another object is to provide novel sealing means for a panel system thatis quickly applied and provides positive sealing engagement betweenadjacent insulated members to assure the integrity of the system forenvironmental conditioning.

A more specific object of the invention is to provide a panel systemforming a refrigerated enclosure or walk-in cooler for the refrigeratedstorage of food products or the like in supermarkets and other stores.

These and still other objects and advantages will become more apparenthereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS For purposes of illustration anddisclosure, the invention is embodied in the parts and in thearrangements and combinations of parts hereinafter described andclaimed.

In the accompanying drawings which form part of the specification andwherein like numerals refer to like parts wherever they occur:

FIG. 1 is a perspective view, partly broken away, of an insulated coolercabinet embodying the modular insulated panel system of the presentinvention,

FIG. 2 is a fragmentary perspective view of a typical side or end panelmodule,

FIG. 3 is a greatly enlarged cross-sectional view taken along line 33 ofFIG. 2,

FIG. 4 is a fragmentary perspective view of a typical bottom or toppanel module,

FIG. 5 is a greatly enlarged cross-sectional view taken along line 55 ofFIG. 4,

FIG. 6 is a fragmentary plan view of one form of panel locking splineembodied in the invention,

FIG. 7 is a fragmentary plan view of another form of panel lockingspline embodied in the invention,

FIG. 8 is a fragmentary perspective view of another form of panellocking spline embodied in the invention,

li Of FIG. 12 is a fragmentary perspective view of a comer post andanother corner locking spline arrangement embodied in the invention,

FIG. 13 is an enlarged cross-sectional view taken along line 13-13ofFIG. 12,

FIG. 14 is a plan view of another panel locking form of spline embodiedin the invention,

FIG. 15 is a plan view of still another form of panel locking splineembodied in the invention,

FIG. 16 is a fragmentary perspective view of one form of sealing gasketembodied in the invention,

FIG. 17 is an enlarged cross-sectional view taken along line 17-17 ofFIG. 16,

FIG. 18 is a fragmentary perspective view of another form of sealinggasket embodied in the invention,

FIG. 19 is an enlarged cross-sectional view taken along line 19-19 ofFIG. 18,

FIG. 20 is an enlarged cross-sectional view taken FIG. 21 is an enlargedcross-sectional view taken along line 21-21 of FIG. 1,

FIG. 22 is an enlarged cross-sectional along line 2222 of FIG. 1,

FIG. 23 is an enlarged cross-sectional along line 23-23 of FIG. 1,

FIG. 24 is an enlarged cross-sectional along line 24-24 of FIG. 1,

FIG. 25 is an enlarged cross-sectional along line 25-25 of FIG. 1,

FIG. 26 is an enlarged cross-sectional along line 26-26 of FIG. 1,

FIG. 27 is an enlarged cross-sectional along line 27-27 of FIG. 1,

FIG. 28 is an enlarged cross-sectional along line 28-28 of FIG. 1,

FIG. 29 is an enlarged cross-sectional view taken along line 29-29 ofFIG. 1,

FIG. 30 is an exploded perspective view illustrating the assemblyprocedure of the bottom panels,

FIG. 31 is an exploded perspective view showing the initial assemblyprocedure of the side and end panels with the bottom and corner post,

view taken view taken view taken view taken view taken view taken viewtaken FIG. 32 is an exploded perspective view showing further assemblyprocedure of the side or end panels with the bottom,

FIG. 33 is an exploded perspective view of the side panel and door frameassembly procedure,

FIG. 34 is a greatly enlarged fragmentary elevational detail of the doorframe side and header panel assembly,

FIG. 35 is an exploded perspective view of the assembly procedure of thetop panels,

FIG. 36 is an enlarged fragmentary perspective view illustratingapplication of a typical sealing gasket,

FIG. 37 is a perspective view ofa special tool used in assembling themodular insulated panel system embodying the present invention,

FIG. 38 is a fragmentary perspective view of still another form ofsealing gasket embodied in the invention, and

FIG. 39 is an enlarged cross-sectional view taken along line 39-39 ofFIG. 38.

DESCRIPTION OF THE PREFERRED EMBODIMENT As previously indicated, apreferred embodiment of the modular insulated panel system inventionherein selected for disclosure purposes comprises a completerefrigerated enclosure of the type known in the refrigeration trade as awalk-in cooler, generally designated by reference numeral C in FIG. 1.The cooler C may be installed in a Room R or suitable space such as thebackroom or processing area of a supermarket having a floor RF and sidewalls RS as shown in FIG. 1. The cooler C includes a bottom section orfloor CF, a top section or ceiling CC and opposed side and end sectionsor walls CS and CE, respectively, defining the enclosure and forming aninternal storage space or area CA accessible through the cooler door CD.Although not shown in the drawings, it will be readily apparent that thearea CA is provided with a suitable source of refrigeration which may bea conventional evaporator unit usually suspended from the ceiling CC andoperated from a remote condensing unit or refrigerated air may be ductedinto the cooler area CA from a remote evaporator unit.

Still referring to FIG. 1, the walk-in cooler C is provided with aplurality of groups or series of insulated modules, partitions or panelmembers of novel and like construction. The bottom section CF comprisesa first series of sequential panel module or members B1 through B6 andthe top section CC comprises a series of similar sequentially arrangedpanel module or members T1 through T6, although the top panel membersare oriented in an inverted position relative to the bottom panels aswill be described more fully. While each I of the side and end wallsections CS and CE comprises a second series of vertical panel module ormembers (and in other installations, such as partition walls, such astraight line series may comprise the entire panel system), the panelmembers of the side and end walls are sequentially designated as SE1through SE12 in a counterclockwise order to correlate with a typicalassembly procedure hereinafter described. In addition, one side or endwall section includes closure panels D1, D2 and D3 defining an openingin which door assembly DA for the cooler door CD is mounted. The sideand end panels SEl-SE12 are sequentially assembled with corner posts P1through P4 to form the rectangular vertical walls of the cooler cabinet.The cooler C may also be provided with a shelf assembly SA, which willbe described more fully hereinafter as will the novel locking membersfor interlocking the panel system in assembled relation and the sealingmembers for sealing between adjacent panel members.

Referring now to FIGS. 2 and 3 wherein a typical side or end panelmodule or member SE (1-12) is illustrated, each of these panels SE is ofpredetermined dimension to accommodate the modular aspect of the panelsystem. For instance, a standard side or end panel may have an 8-footvertical dimension and a width of 4 feet, except that the panels Seabutting the comer posts Pl-P4 will be narrower by the lateral dimensionof the corner post, Le, a 2-inch post will require adjacent panels of 46inches.

Each panel member SE (ll-l2) comprises inner and outer surface casingsor liners 2,2a of rectangular configuration and having peripheral edgesor margins 2b,

the liners 2,2a being spaced apart by peripherally aligned end caps oredge channel members 3 of generally T-shaped configuration to define acentral cavity filled with and providing a foam insulation body 4 ofpolyurethane or the like. The liners 2,2a are preferably formed of coldrolled commercial quality sheet steel or the like, and the edge orchannel membets 3 are preferably formed of extruded plastic, such asAcrylonitrile Butadine Styrene (ABS).

1 As shown best in FIG. 3, the edge or channel members 3 extendlongitudinally along each peripheral margin of thepanel member SE or, inother words, the panel member is enclosed by opposed pairs of lengthwiseand laterally extending members 3 of identical configuration arranged inoverlapping and contiguous relationship with the juxtaposed marginaledges 2b of the liners 2,2a. The edge or channel members 3 are providedwith spaced apart base portions 5,5a having exterior and interior sidesor surfaces 5x,5i and first or liner abutment flanges 6,6a areintegrally formed on the base portions 5,5a to define the lengthwiseside edges thereof and extend normal to the base portions substantiallyparallel with the liners 2,2a. Closely adjacent to and extending in aparallel direction with the outer liner abutment flanges 6,6a areanother set of locking flanges 7,7a, these. second flanges 7,7a beingintegrally formed with the base interior surface 51' at a slight outwardangle therewith to define with the adjacent side flange 6,6d wedge orkey-stone shaped channels 8,8a therebetween extending lengthwise of theedge members 3. A pair of opposed, spaced channel walls 9,9a are alsointegrally formed with base portions 5,5a adjacent to the mid-portionthereof to form the T-shaped configuration and define an elongatedspline receiving groove, slot or channel lengthwise of the baseextending peripherally around the entire side or end wall panel SE. Abase or cross wall 1 1 is integrally formed across the walls 9,9a toclose the groove 10 and includes integrally formed extensions 11a fordisplacement preventing bonding engagement with the insulation body 4.If desired, strengthening or reinforcing members 12,12a, such as rigidnylon or metallic strips, may be extruded into the channel walls 9,9a ormay be bonded to either surface of the channel walls 9,9a. A pluralityof opposed aligned pin receiving V bores or apertures 13,13a areprovided through the groove walls 9,9a and reinforcing members 12,12a inpredetermined spaced relation lengthwise of the edge members SE, andaplurality of spline locking lugs or pins 14 are pressed into and fixedlyreceived in said opposed apertures l3,13a extending across the groove10. It should be noted that the location and spacing of pins 14 in therespective panel members SE, B and T are specific in order to assureclosely adjacent or abutting interlocking engagementtherebetween by thelocking members to be described. As shown in FIG. 2, the lateral orshorter ends of a typical standard panel SE are provided with four pins,and the longitudinal or vertical sides are provided with seven pins 14,although other pin locking arrangements may be provided. In addition,longitudinally extending serrations or grooves 15,15a are providedlengthwise of the base portions 5,5a in the exterior surface 5x thereofintermediate to the flanges 6,611 and central channel 10 for sealingpurposes, as described hereinafter.

Still referring to F I63. 2 and 3, in the assembled relationship of thecomponents of the side and end panels SE, the extruded channel or firstmembers 3 areprovided with the reinforcing strip elements 12,12a and thepins 14 are pressed into the opposed openings 13,13a in channel walls9,9a. The channel members 3 are cut to end and side length with miteredends and the liner or second members 2,2a are positioned with themargins 2b in the wedge-shaped channels 8,8a in abutment with the outerflanges 6,611. A specific or predetermined amount of polyurethane orlike plastic is provided for each panel module SE and, in applying thefroth foaming process, the plastic expands to completely fill theinterior panel space to surround the pins 14 and channel walls 9,9a,11,.11a and extend into the wedge-shaped channels 8,8a to firmly holdthe liner margins 2b against flanges 6,6a. It should be noted that nootherfastening means or the like are utilized in forming the panelmembers SE.

Referring now to FIGS. 4 and 5 wherein a typical intermediate bottompanel module or member B (2-5) or top panel T (2-5) is illustrated, eachof these panels is of similar construction to the side and end panels SEand of predetermined dimension to accommodate the modular aspect of thepanel system. For instance, a standard intermediate panel may have an8-foot length to correspond to the width of twoend panels SE and twocorner post P and the lateral or end dimension similarly will be 4 feet.

The end or closure bottom panel members B1 and B6 (or top panels T1 andT6) are also of similar construction, but are dimensioned with shorterlateral ends, such as 2 feet to provide an overlapping or offsetrelationship between the joints of the bottom and top walls CF and CCrelative to the joints of the side and end walls SE.

Still referring to FIGS. 4 and 5,, each of the intermediate panelmembers B (or top panels T) comprises inner and outer surface casings orliners 16,16a having peripheral edges or margins 16b, but the innerliner 16 is predeterminately shorter than the outer liner 16a.

The bottom panel member B (or top panel T) is provided with the T-shapededge channel members 3 (identical to those described with reference toside panels SE in FIGS. 2 and 3) extending along its outer longitudinalsides to adjacent the ends. The lateral ends of the intermediate panelsB are provided with L- shaped channel members 17 engaged in overlappingcontiguous relationship with the juxtaposed marginal edges 16b of theliners 16,]l6a as described hereinafter, with insulation material 4being formed into the interior chamber of the panel B in bondingrelation with the liners 16,160 and edge members 3,17.

The L-shaped edge or channel members 1-7 are formed of extruded plastic,such as Acrylonitrile Butadine Styrene (ABS), and comprise spaced apartchannel forming walls or legs 18,1830 including first or liner abutmentflanges and an end wall or leg 19 formed at right angles thereto, thebase walls 18,1811 extending in the plane of the short liner l6 and theend walls 19 extending normal thereto and defining the lateral endmargins of the panel B. The spacedl base walls 1818a have exterior andinterior sides or surfaces l8x,l8i and the inner surfaces l8i of basewalls 18 adjacent the free margin thereof form abutment surfaces for theend margins 16b of the shorter panel liner 16. Locking or second flangesare angularly formed from these inner surfaces l8i to define wedge orkeystone-shaped channels 21 with the base walls 18. Similarly, the endwalls 19 of the channel members 17 are provided with right-angle edgeflanges 19a extending in the plane of the other liner 16a and forming asurface abutment with the end margins 16b thereof, and locking flanges20b are formed from the end walls 19 extending in a parallel directionwith the edge flanges 19a and defining therebetween wedge orkeystone-shaped channels 21a.

Each of the L-shaped channel members 17 is also provided with a pair ofopposed spaced channel walls 22,22a integrally formed with the base wallportions 18,180 to form a T-shaped configuration similar to the channelmembers 3 and define an elongated spline receiving groove, slot orchannel 23 lengthwise of the base walls 18,18a extending parallel withand adjacent to the end wall 19 at each lateral end of the panel memberB. A cross wall 24 interconnects the inner ends of the channel walls22,22a to close the channel 23, but does not extend laterally beyondinto the body cavity in order to facilitate the flow of plastic into theend channel members 17 during fabrication. The channel walls 22,22a mayalso be provided with reinforcing strip members 25,25a extruded thereinor bonded thereto, and spline locking lugs or pins 26 are pressed intoopposed openings 27,2711 in predetermined spaced relation along thechannel 23 and project outwardly of the channel walls 22,22a into thebody cavity. These pins 26 are also specifically located to assurepositive interlocking relationship between panel members. A series ofadjacent serrations or grooves 28 are formed in the exterior surface 18xof the base wall portion 180 adjacent to the outer end wall 19 forsealing purposes. In addition, the L-shaped channel members 17 areprovided with end caps 29 of rectangular shape and bonded to the basewalls 18,18a and end wall 19 to close the ends of the channel memberswhen assembled with the liners 16,16a and side channel members 3, theend caps 29 having grooves 29a conterminous with the channels 23. Itwill thus be apparent that the channel means 23,29a extend across theend portions of the inner panel member surfaces and are open whereas thechannels 10 of the channel members 3 forming the longitudinal sides ofthe intermediate panel members B terminate at the end caps 29 and areclosed by a suitable cap to retain the insulation material in the bodycavity.

The assembled relationship of the components of the intermediate bottompanel modules or members B (or top panels T) is similar to thatpreviously described with respect to the side and end panels SE, and thefoam insulation comprises the means for holding these componentstogether without other fastening means being needed. It should be notedthat the wedge-shaped channels accommodate a sufficient tapering body offoam material to prevent the edge channel or first members 3,17 frompulling loose from the peripheral margins 211,161) ofthe liner or secondmembers and also provide a bonding continuity with the main body ofinsulation 4. It will also be understood that the so-called wedge-shapedchannels may be different configurations, and the term wedge orkeystone-shaped channels is intended to cover all such alternateconfigurations.

Referring now to FIGS. 30 and 31 which illustrate steps in an assemblyprocedure for the panel system, it will be noted that the end or closurebottom panel members B1 and B6 (and, similarly, the top panels T1 andT6) are formed differently than the intermediate bottom panels 82-5 (andtop panels T2-5). Only one longitudinal edge of the panel member B6(FIGS. 30 and 31) has a T-shaped channel member 3 extending betweenL-shaped channel members 17 at the short lateral ends of the panel B6,and the other side is pro vided with an L-shaped channel member 17formed with mitered corners to form a continuous upwardly openingconnecting channel 23 in the upper panel surface (16) extending alongthe two short ends and outer longitudinal side. The door panels D1, D2and D3 are similar in construction to the other side and end wall panelmembers SE, but the dimensions thereof will be determined by the widthand height of the door CD.

The assembly or fabrication procedure for all panel modules (SE, B, Tand D) is similar and, accordingly, the fabrication of only one suchpanel member SE will now be described. The edge channel or first members3 are arranged in a suitable fixture or jig (not shown) to form therectangular edge framing of the panel SE with the liner or secondmembers 2,2a being positioned between the opposed flanges 6,8 and 6a,8a,respectively. The liners 2,2a are positioned and held against the outerflanges 6 and 6a such as by an opposed vacuumtype supporting platen (notshown) in surface contact therewith and forming a vacuum on the surfacesof the liners 2,2a while completing the supporting fixture to maintainthe liners in spaced parallel planes during the foaming process. Anaperture (not shown) is formed in one edge member 3 to receive theinjection nozzle of conventional froth foaming equipment, and aregulated and predetermined amount of raw polyurethane or like plasticinsulation material is injected into the body cavity of the panel memberSE according to conventional froth foaming techniques. The nozzle isthen removed and the aperture plugged during the period that theexpanding foam material essentially fills the voids in, around andbetween the liners 2,2a and channel members 3 and cures to form a solidbond with the liners and channel members to set the pins 14 in thechannel walls 9,9a and form locking wedges in the keystone channels 8,8ato firmly engage the liner margins 2b against the outer edge member lipsor flanges 6,6a. When the insulation is cured or set, the plug (notshown) is removed and the aperture may be filled or dressed in asuitable manner.

The respective panel members herein disclosed are assembled together toform the panel system of the walk-in cooler C with the use of splineconnecting or locking members S1 (FIG. 6), S2 (FIG. 15), S3 (FIG. 7) andS4 (FIG. 14). The splines 81-84 are each provided with a body 30 of flatstrip steel or the like having a predetermined width, length andthickness adapted to be received in the panel grooves or channels 10,23,the outer edges or margins 30a,30b being provided on the body. As shownin FIG. 6, the spline S1 is provided with a plurality of like pinreceiving bayonet slots 31,3la in predetermined spaced relation in theopposed edges 30a,30b thereof, respectively, for guiding and lockingengagement with the cooperating pins 14 of certain channel members 3 ofthe panel members SE, B, T and D, and the spline S3 is provided withsimilar pin receiving bayonet slots 32,32a in its opposed edges 30,30a.The spline member S3 is used for locking engagement between cooperatingpins 14 of side and end panels SE with cooperating pins 26 of bottompanels B, but not the top panels T.

The bayonet slots 31,3la and 32,32a of splines S1 and $3 each comprisesan entry opening 330 to an elongated slot 33b extending lengthwise ofthe spline members 81,83 to a rounded pin abutment or seating surface330, the entry opening 33a being defined on one side of an angular camsurface 33d connecting with the inner side of the slot 31,32 and theother side of the entry opening 33a has a rounded and inwardly slopingguide surface 332. In addition, tool slots 34 are centrally positionedadjacent each end of the splines 81 and S3 for use in assemblyprocedures and using a tool 35, FIG. 37. The tool 35 is formed of rigidsheet steel and has a keystone-shaped working portion 35b with inwardlyconverging margins 35b for positive engagement in slots 34, and a body35c with end striking margins 3Sd for hammer actuation of the tool 35and the spline member being driven thereby. It will be noted that theslots 31,32 on both splines S1 and S3 are formed on the opposite margins30a,30b with the pin abutment margins 330 in lateral orientation fordirect opposed or lateral alignment of pins 14,26 as will be described,and that the bayonet slots 31 of the spline S1 formed in each margin30a,30b are oriented in the same longitudinal relationship whereas theslots 32 in spline S3 are offset and reversely formed on opposite sidesthereof.

Referring to FIG. 15, the spline locking member S2 is adapted forcooperation only in conjunction with the spline S1 in certain panelinstallations in which a structural supporting or reinforcing spline isrequired. The spline S2 is provided with opposed pairs of Ushapedopenings or pin receiving slots 36,360 extending laterally inwardly inpredetermined longitudinally spaced relationship for releasably securingor locking engagement with the cooperating pins 114 of the panels.Elongated key-ways or slots 36b are provided in the body 30 of thespline member S2 and is of sufficient length to permit relativelongitudinal movement of splines 81 into locking engagement.

Referring to FIG. 14, the spline S4 comprises a special final panellocking spline for the header panel member D3 over the door assembly DAillustrating one final closure arrangement for a panel system forming acomplete enclosure, such as the cooler C. The spline S4 is a shortlocking member having only single bayonet slots 37,370 formed in eachouter margin 30a,30b thereof similar to the slots 32,32a of the splineS3 and having similar numerals for like identifying parts. However, theslot (37a) on one side of the spline member S4 is extended from the pinabutment margin 336 to the end of the spline to form a marginal edge 30cadapted for end entry into a channel l rather than laterally through anentry opening 33a as in splines 51 and S3.

Referring to FIGS. 10, 11 and 22 wherein a typical corner post P isshown, the post P is a square (2X2) wooden center post 40 provided witha suitable outer casing 40a compatible with the panel system finish and,

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preferably, a plastic casing is extruded directly onto the post 40. Thecasing 40a has smooth exterior surfaces 40b on diagonally oppositecomers 40c, and a plurality of parallel vertical serrations 46d areformed in each exterior surface immediately adjacent to the otherdiagonal comers 40c for sealing purposes to be described. The post P isprovided with a corner spline locking or connecting member S5 ofgenerally W- shaped configuration utilized for interlocking engagementbetween adjacent corner-defining panel members SE, the spline S5 havingright angularly disposed base walls 41,41a in abutting relation on oneof the diagonal corners 40c and being secured to the post P by screws4112 or like fasteners. Rigid steel flange or spline walls 42,42a areformed integral with the base walls 41,4141; respectively, and extendoutwardly at right angles thereto centrally of the sides of post P andhave free outer margins 43,43a in which a plurality of vertically spacedbayonet slots 44,44a are formed. The slots 44,44a are identical to theslots 31,3la of spline S1 (FIG. 6) and are also laterally aligned andlongitudinally oriented in the same direction. It should be noted thatthe base walls 4l,4la of the spline S5 may extend to the ends of thepost P, but the ends of spline flanges 42,42a are spaced from each endof the post to obviate interference with the relative sliding lockingaction of splines S1 and S3 during assembly.

As indicated, the cooler C may include a shelf assembly SA, as shown inFIG. l, which will'comprise at least one shelf 45 supported on shelfbrackets 45a vertically adjustably mounted on one or more interior wallsof the cooler. It will be understood that neither of the shelves 45 orshelf supporting brackets 45a form a part of this invention, but thatsuitable standards must be provided to accommodate the attachment to andvertical adjustability of such shelves and shelf brackets on theinterior walls. Referring to FIGS. 8 and 9, a combination shelfsupporting standard and spline locking member S6 comprises a lockingspline or connecting body portion 46 and shelf standard body portion 47,which may be formed separately and welded together or which may beformed as an integral member, as shown. The spline portion 46 isessentially identical in construction to the spline S1 and substitutestherefor where shelves 45 may be desired, and includes outer margins48,48a in which laterally aligned and longitudinally oriented bayonetslots 49,49a are formed as in spline S1. The shelf standard 47'comprises an elongated tubular member 56 having predeterminatelyvertically spaced notches 50a adapted to receive the mounting lugs of ashelf support bracket 45a in a conventional manner, and the tubularstandard member 50 is secured to or formed with the spline body 46intermediate to the margins 48,48a by a connecting web 51 extendingnormal to the spline flanges on body 47 and of sufficient depth to spanone base portion 5,5a from the channel 10 of a side panel member SE toposition the spline body 47 in the channel 10 with the tubular standard50 projecting beyond the panel wall 2. It will be noted that the upperand lower ends of the spline body 46 are shorter than the verticaldimension of the standard portion 47 as in the configuration of thecomer post P whereby the upper and lower lateral channels of edgemembers of the side panels SE interconnected by the spline S6 will notbe obstructed for relative sliding movement of a transversely extendingspline member (S1,S3) crosswise of the ends of spline S6. In addition, atop wall CC support plate 52 may be welded or otherwise secured to theupper end of the shelf standard tubular body 50 and web 51, and isprovided with openings 52a for supplemental attachment to the top wallpanel T as with screws or the like (not shown).

Referring to FIGS. 12 and 13, a similar shelf bracket standard 53 may beprovided on a corner post P, the standard having an angular base wall 54abutting the base walls 41a,41b of a corner spline SS and being weldedor otherwise attached thereto and the web 50a and tubular bracketmounting portion 50 projecting at a diagonal angle to the corner post P.

In connection with the shelf assembly SA and with reference to FIGS. 27,28, 38 and 39, a novel sealing gasket or cover member G1 is provided forthe shelf bracket standard 47,53 to prevent entrapment of foreign matterin the tubular portions 50 and to provide an interior seal of the jointsbetween adjacent side walls SE interlocked by the spline and bracketstandard member 36. The cover member G1 is preferably extruded from asuitable flexible plastic, such as Ethylene Vinyl Acetate (EVA), andcomprises an imperforate U-shaped body 56 having an interior wall 56aadapted to snugly receive and encase the tubular portion 50 of the shelfstandard body 47 and a pair of diverging wing flanges 56b are formedintegral therewith and have converging or tapering walls to providelongitudinal sealing lips 560 at the free edges. The U-shaped body 56and wing flanges 56b are joined by a reduced wall thickness created by alongitudinal recess in the outer walls 56d to increase the flexibilityand resiliency of the flanges and sealing lips for firm sealing abutmentwith the panel member walls 2. The imperforate body 56 is pressed overthe tubular standard body 50 and, when the shelf bracket location isdetermined, a notch or kerf 562 (indicated in broken lines in FIG. 38)is made in the body 56 at the appropriate shelf standard notch 50a.

Referring to FIGS. 16, 17, 22, 23, 24, 26 and 36, the form of novelsealing or gasket member G2 shown is adapted to be utilized in bothexterior and interior sealing of vertical joints between adjacent panelsand exterior sealing of horizontal joints between adjacent panels. Thisgasket member G2 is also extruded from a suitable flexible plastic, suchas Ethylene Vinyl Acetate (EVA) into elongated sealing strips cut topredetermined length. In cross-section, the gasket member G2 comprisesan arcuate outer flange or head portion 57 and an inner body portion 58formed integral with the head portion 57 at the central portion andextending normal thereto. The head portion 57 has a thicker centralportion 57a and the arcuate flange walls 57b converge or taper to formlongitudinal sealing lips 570 at the outer free margins. The bodyportion 58 is also thicker at its juncture with the head portion (58b)and has converging or tapering walls 58b, and a plurality of directlylaterally opposed V-shaped sealing lips 580 are formed on the body 58 atan outward angle extending toward the head portion 57.

Referring to FIGS. l8, 19, 22 and 25, another form of novel sealing orgasket member G3 is shown to be utilized in sealing both horizontallyand vertically extending interior corner joints, this gasket member G3may also be extruded of EVA or the like. The gasket member G3 has anarcuate outer flange or head portion 59 and an inner body portion 60formed integral with the head portion intermediate its lateral edges.The head portion has a thicker central portion 59a and the arcuate,laterally extending flanges have tapering walls 59b forming longitudinalsealing lips 590 on the free margins. The body portion 60 has angularlyrelated wall sections with a thick wall portion 60a connecting with thehead portion 59 and extending normal thereto and a tapering wall portion60b extending angularly therefrom. A plurality of opposed V-shapedsealing lips are formed on the body portion 60, but are offset relativeto each other with a single major lip 600 being formed on the open,obtuse side at the juncture of the wall sections 60a,60b to extend in aplane substantially parallel with the general plane of the head portion59 and a pair of minor lips 60d being formed on the other side of wallsection 60b beyond the major lip 600 from the head section 59 at anoutward angle extending toward the head section 59.

In addition to the sealing members G1, G2 and G3, conventional elongatedgasket strips or tapes G4 of rectangular cross-section are utilized oncertain joints of the panel members B and SE on the exterior sidesadjacent to the floor RF and side walls RS of the room and the exteriorjoints of the ceiling panels T also may be provided with the gasketstrips G4 although in many installations, where ample overhead clearanceis provided, the gasket member G2 may be used.

I Referring briefly to FIGS. 1, 20 and 21, the interior floor of thecooler C may be covered by any suitable planking to prevent concentratedstresses upon the panel members B and translate any forces laterally ofthe centers of such panels through the edge members 3,17 to the floorRF. For instance, tool grade fiberboard sheets 61, such as MasoniteBenelex may be used, and the joints between panels and around theperiphery may be sealed with a suitable caulking or resilientthermo-expansion material 62.

Referring now to FIGS. 1, 29 and 33, the door'assembly DA comprises amain exterior frame 63 having side and header frame members 63a and 63b,respectively, formed of extruded fiberglass, plastic or the likecompatible with the cooler panel construction. The frame members 63a,63bhave foam insulation sections 64 and a wooden core section 644 separatedby mullions 64b, the wood core 64a comprising a mounting post for thedoor CA, and plural hinge bases 65 being secured thereto. A peripheralflange 66 is formed to abut the adjacent door panel D1, D2 or D3 and arubber adhesive seal tape 66a is provided therebetween. The exteriorframe 63 is secured in place with the panels D1, D2 and D3 by aninterior T- shaped frame 67, such as an aluminum extrusion having sideand header members 67a and 67b, respectively, with outer peripheralflanges 67c abutting the panels D1, D2 and D3 in opposed relation withthe flanges 66 and inner flanges 67d secured to the outer frame 63 bymolyjacks and machine screws 68 or the like. Rubber adhesive sealingtape 68a is also applied between the flanges 67c, 67d and the panels Dand outer frame 63, respectively.

1. A panel module for a panel system of the type described comprising anedge forming member including a base wall having laterally spaced outeredges, and adjacent flanges connected to said base wall in opposedspaced-apart relation and being relatively angularly related to eachother defining a wedgeshaped channel therebetween, a liner member havingan edge margin disposed between said flanges and being in surfaceabutment with one of said flanges and spaced from the other of saidflanges, and bonding means comprising foam insulation material that isexpanded into said channel between the other of said flanges and saidliner member and hardened in bonding engagement therein to maintain saidedge forming and liner members together.
 2. The panel module accordingto claim 1, wherein said spaced-apart flanges include a first flangeextending from adjacent to one lateral edge of said base wallsubstantially in the plane of said liner member and a second flangeextending from said base wall angularly and adjacent to said firstflange.
 3. The panel module according to claim 2, including another pairof angularly disposed spaced flanges formed adjacent to the otherlateral edge of said base wall to define another wedge-shaped channel,and another second liner member positioned in surface abutment with theoutermost of said other pair of flanges and maintained therein by saidbonding means.
 4. The panel module according to claim 3, in which saidliner members extend from said first-mentioned and other wedge-shapedchannels in predetermined spaced parallel planes forming opposite andsubstantially planar surface walls of said panel module, and said foaminsulation material forms the sole means for interlocking said edgeforming and liner members together.
 5. The panel module according toclaim 1, wherein said base wall of said edge forming member is separatedinto laterally spaced segments, and opposed walls being formed on saidbase wall segments and extending normal thereto to define an elongatedrecessed central channel extending substantially throughout the lengthof said edge forming member.
 6. The panel module according to claim 5,in which a rigid strip of reinforcing material is positioned within eachof said opposed channel forming walls.
 7. The panel module according toclaim 5, in which a cross wall interconnects said channel forming wallsand defines the bottom of said central channel, and said cross wall isprovided with lateral protrusions extending beyond said spaced channelforming walls toward said pairs of flanges and in spaced relation withsaid base wall segments.
 8. The panel module according to claim 5, inwhich said opposed walls have laterally aligned openings, and aplurality of laterally extending pin means being positioned in saidopenings in predetermined longitudinally spaced relationship across thecentral channel of said edge forming member.
 9. The panel moduleaccording to claim 8, in which said edge forming member is T-shaped incross-section and said opposed channel walls extend perpendicularly fromsaid base wall segments to define said central channel, and saidspaced-apart flanges being formed on the lateral edge of at least onebase wall segment remote from said central channel.
 10. The panel moduleaccording to claim 8, in which said edge forming member is L-shaped incross-section and said laterally spaced base wall segments are in theplane of said liner member with adjacent edges from which opposed wallsextend perpendicular to define said central channel, and an end wallextending normal to the plane of said liner member from the lateral edgeof at least one base wall segment remote from said central channel. 11.An insulated panel comprising a pair of opposed liner means each havingopposed pairs of marginal edge portions, at least one edge portion ofone of said liner means being juxtaposed with one edge portion of theother of said liner means, opposed pairs of edge members connected inend-to-end framing relation between said liner means in enclosingengagement with said opposed pairs of edge portions thereof, a bodycavity formed between said liner means and said edge members, at leastone of said edge members including a base wall extending between saidliner means and substantially normal thereto, a pair of opposed sidewalls integral with said base wall, a pair of flange means integrallyconnected with said base wall adjacent to said side walls and definingtherewith a pair of substantially wedge-shaped channel means open tosaid body cavity, one edge portion of said one and other liner meansbeing respectively received in said channel means and engaged with saidside walls, and an integral mass of insulation material in said bodycavity and extending into said channel means in bonding relation betweensaid liner means and edge members for preventing displacement of saidone edge member from said panel.
 12. An edge member for an insulatedpanel comprising an extruded plastic body of preselected length, a basewall on said body having interior and exterior surfaces and laterallyspaced outer margins, a pair of outer side walls integrally formed onthe outer margins of said base wall defining the width of said edgemember, flange means integrally connected with the interior surface ofsaid base wall adjacent to each of said side walls and angling from saidbase wall toward said side wall to define a wedge-shaped channeltherebetween, said base wall including a pair of opposed second wallmeans integrally connected with said base wall adjacent to themid-portion thereof and laterally spaced from said outer side walls, across wall integrally connected between said wall means and spaced fromsaid base wall, said wall means and cross wall defining a continuouselongated central channel extending substantially throughout the lengthof said base wall, a plurality of opposed and aligned aperture means insaid second wall means, and being predeterminately longitudinally spacedfrom each other lengthwise of said body, and a plurality of pin meansreceived in said plural opposed aperture means and extending across saidcentral channel.
 13. A modular insulated panel enclosure having acontrolled environment, comprising a first series of horizontallydisposed panel members forming a bottom wall, a second series ofvertically disposed panel members forming opposed side and end walls, athird series of horizontally disposed panel members forming a top wall,corner members disposed between adjacent side and end walls, doorassembly means in one of said side and end walls, adjacent panel membersin each of said first, second and third series having continuous opposedchannel means with a plurality of longitudinally spaced pins therein,first spline members having slots engaged with said pins in opposedchannels and interlocking said adjacent panel members together, secondspline members on said corner members in interlocking relationshipbetween adjacent side and end wall panels, Shelf means includingvertical shelf mounting standards connected with certain of said splinelocking members and positioned adjacent to the interior surfaces of saidsecond series of panel members substantially at the juncture of adjacentpanel members, yieldable sealing members having plural sealing lipssealably engaged between adjacent panel members of said first, secondand third series and other sealing means covering said shelf standardsand having spaced wing flanges with sealing lips engaged against saidinterior surfaces adjacent to the juncture of adjacent panel members.